Blank handling apparatus



Jan. 7, 1969 T, M, BAUM 3,420,387

BLANK HANDLNG APPARATUS Filed Jan. 5, 1967 INVENTOR. THEODPE M. BA1/MSheet 2 of 4 Jan. 7, 1969 T. M. BAUM A BLANK HANDLNG APPARATUS FiledJan. 1967 mi QQ Jan. 7, 1969 T. M. BAUM BLANK HANDLNG APPARATUS SheetFiled Jan. 5, 1967 'INVENTOR. m5000915 M. BAUM BY w ',d

/ll's dm- Jan. 7, l1969 T. M. BAUM BLANK HANDLING APPARATUS Sheet FiledJan. 5, 1967 United States Patent O 4 Claims ABSTRACT F THE DISCLOSUREApparatus for stacking a preselected number of corrugated blanks fortying into a bundle for shipping purposes comprises a first stacker forforming the individual blanks that are fed from a folder-gluer into lastack yby action of an oscillating plate acting against the trailingedges of the blanks to square the blanks and force the leading edgesagainst a feed gate; a reciprocating feeding mechanism for feeding thebottornmost blank from the first stack to a final stacker Where a secondstack of blanks of predetermined number is formed on a continuouslyrunning conveyor by blanks fed to the underside of the second stack. Theconveyor urges the leading edges of the blanks against 'a pair ofstop-gates while a front guide for the trailing edges of the blanksprevent the stack from tipping over. The feeding of blanks from thefirst stack is interrupted upon completion of the final stack andsimultaneously the stop-gates are pivoted out of engagement with thesecond stack to permit the removal of the stack by the conveyor.

This invention relates to stacking apparatus for receiving theindividual blanks froma folder-gluer and for stacking the blanks into astack of a predetermined number of blanks for tying and shipping as abundle. Blanks folded and glued in conventional folder-'gluer machinesoften leave the folder-gluer machine in an out of square condition. Thiscondition, of course, must be corrected lbefore the glue dries. It isdesirable to have these individual blanks piled in a stack forsubsequent bundling. In view of floor space and material handlingconsiderations, it is also desirable to accomplish squaring and stackingin a straight line operation immediately following the foldergluer. Itis additionally helpful to have the squaring and stacking accomplishedat substantially the same level that the blanks leave the folder-gluer.Since the folderdgluer is capable of processing blanks of various sizes,blanks squaring and stacking machines must possess a capability forhandling blanks whose dimensions may vary widely. Besides this, itpreferably is adjustable to provide stacks of blanks of preselectedvarying numbers for subsequent bundling preparatory to shipping.

The present invention provides apparatus for automatically stacking,squaring and delivering stacks of blanks of predetermined number at aposition which is in lateral and substantial horizontal alignment with afolder-gluer machine. The invention contemplates a first stacker forreceiving individual blanks from the folder-gluer, a final stacker forreceiving individual blanks from the first stacker, a feed for feedingindividual blanks from the first stacker to the final stacker at a rategreater than the individual blanks are received by the first stacker anda conveyor for discharging from the final stacker a stack of apredetermined number of individual blanks, and controls for stopping thefeed during the discharge of the stack from the final stacker.

The above and further objects and novel features of the invention willappear more fully from the following detailed description when the sameis read in connection with the accompanying drawings. It is to beexpressly understood, however, that the drawings are not intended lCC asa definition of the invention but are for the purpose of illustrationonly.

In the drawings wherein like parts are marked alike:

FIGURE 1 is perspective view of the novel apparatus as it would appearwhen used in connection with a foldergluer and delivery conveyor, bothof the latter being shown in phantom lines;

FIGURE 2 is a side elevation of the apparatus shown schematically tobest illustrate its operation;

FIGURE 3 is a top view of the stopgates in partial crosssection showingthe two positions of the gates;

FIGURE 4 is a Schematic diagram for the power train of the machine; and

FIGURE 5 is a wiring diagram of the electrical controls for the machine.

Referring to FIG. 2, there is provided a first stacker 7 foraccumulating blanks 10 in 4a stack 11 as they are received in sequencefrom =belt 12 of a folder-gluer machine 16; a second stacker 13 foraccumulating a final stack 15 of a preselected number of blanks; and afeeder comprised of feed rolls 33 and a reciprocating mechanism 34 foroperatively connecting the stackers by feeding successive bottornmostblanks from the first stack 11 onto the bottom of the second stack 15until the desired number of blanks are in the second stack 15, and acontrol system, FIG. 5, for interrupting the feeding of the bottornmostblanks to the second stack 15 after a desired number of blanks have beenfed to the second stack, and for discharging the final stack 15 ofblanks from the machine and onto a conveyor 124 during the time that thefeeding is interrupted and thereafter for continuing the feeding andstacking sequence.

The blank 10, FIGS. 1 and 2, is shown as it is being discharged frombetween a conveyor 12 and pressure rollers 14 of a conventionalfolder-gluer 16. Blank 10 enters into the first stacker 7 and undergoesthe first phase of the stacking, squaring, and delivering operation inthis portion of the machine that is hereafter referred to as thesquaring-compression section. This first phase consists of accumulatingthe individual blanks 10` as a stack 11 of blanks and concurrentlysquaring the stack. The blanks have been folded into a tubularknocked-down carton shape in the folder-gluer as indicated generally at18 in FIG. 1. Blank 10' has a corner tab 20 which has been glued to acorner of the blank. Since the blank may not be folded perfectly squarein the folder-gluer 16, 'a squaring plate assembly 28 is provided atstacker 7 to square the blank before the glued tab 20 has a chance toset.

The first stacker or squaring-compression section 7 comprises a pair ofpull rolls 22, 24 for maintaining control of the blanks as they leavethe folder-gluer 16; :a feed gate 26 for arresting the forward travel ofthe blanks and (as will be later described) for metering the flow ofblanks to the second stacker or bundle-ejector section 13; anoscillating squaring plate assembly 28 ata position opposite thefeed-gate 26 for periodically spanking the trailing edges of the blanks,thereby urging their leading edges against the feed gate 26 with enoughforce to square the blanks; a feed bed 30 for supporting the blanks :asthey settle to form a stack cooperative with the feed gate 26 so thatthe leading edge of the bed forms a gap 32 between the bed and thebottom of the feed gate 26 for metering only the bottornmost blank intothe bundle-ejector section 13; a reciprocating feed mechanism 34 forengaging the trailing edge of the bottornmost blank and urging the blankforward into gap 32 where feed rolls 33 feed it into the bundle-ejectorsection 13 as the lowermost blank and a feed interruptor 36 which isactuated after a preselected number of blanks have been fed to thesecond stacker 13 to raise the trailing edge of the stack to preventengagement by the feeder 34 for an interval of time after which time thestack is lowered and the feed cycle is repeated.

The blank enters stacker 7 by way of a pair of pull rolls 22, 24 whichare journaled for driven rotation between a pair of spaced apart sideframes 38L, 38R. These rolls are positioned at a level to receive theblanks 10 from the folder-gluer in the nip formed by the rolls. Upperroll 22 is journaled in conventional eccentrics (not shown) which can besimultaneously rotated in the known manner to move roll 22 closer toroll 24 to suit the caliper of the blanks.

Upper roll 22 is made by securing a pair of laterally spaced collars 23for rotation with a shaft 25. The collars 23 preferably have an outerelastomeric covering such as synthetic rubber to aid in gripping theblanks. The collars 23 are adjustable axially of shaft 25 so that theymay be positioned to grip the blanks at any desired location, usuallynear the lateral edges. They may be secured in the selected location bymeans of set-screws (not shown).

Lower roll 24 is made by securing several laterally spaced collars 27for rotation with a shaft 31 defining spaces 33 between them having awidth about equal to that of collars 27. Col-lars 27 are similar tocollars 23 except that they ordinarily remain in a fixed location ratherthan being adjustable axially.

The forward movement of the blanks is arrested b-y a feed-gate 26 whichcomprises a lateral plate 40 having each end slidably nested in verticalslots 42 formed in the bundle-ejector side frames 44L, 44R. The plate 40is raised or lowered to permit only one blank to pass through the gap 32into the bundle-ejector section. Vertical adjustment is accomplished byrotating a pair of rods 46 threaded into plate at location 48. Rotationof rods 46 is effected by a pair of conventional miter gear assemblies50 connected to the rods 46 and to a common cross shaft 52 which isrotatably secured between the side frames 44L, 44K.

The stack of blanks is maintained in alignment or squared by way of anoscillating squaring plate assembly 28, particularly by a plate 54 thatis pivotably supported by a cross shaft 56 which, in turn, is supportedbetween side frames 38L, 38R. When plate 54 is in the vertical position,one face of plate 54 is coplanar with the trailing edges of the blanksin the stack. When the plate is oscillated about shaft 56, plate 54moves away from the stack at an angle and then returns to coplanarContact. If any of the blanks are out of square, some of the edges ofthe blanks will protrude beyond the desired planar surface (both leadingand trailing edges), and the plate 54 will force them into alignment byspanking the blank against the feed gate 40. It can be observed thateach blank may be subjected to the spanking action several times as theblank moves downward in the stack.

Oscillation of plate 54 is accomplished by connecting the plate by aconnecting rod 58 to a drive shaft 60 which has an eccentric 62connected for rotation therewith. Connecting rod 58 encircles theeccentric 62 so that as the drive shaft rotates, the rod 58 is caused toreciprocate and, being connected to plate 54 by a conventional pinconnection 64, causes plate 54 to oscillate about cross shaft 56 towhich it is pivoted. In the event the folder-gluer is subsequentlyimproved to the extent that the folded blanks are squared prior toleaving the machine, the squaring plate assembly 28 would not berequired. The squaring-compression section would operate substantiallyin the same manner except that plate 54 could be stationary.

The stack 11 of blanks accumulates or piles up on a feed bed 30. Anumber of spaced apart slats 66 constituting bed 30 extendlongitudinally of blank travel with their downstream ends secured to across member 68 mounted between side frames 44L, 44R. The upstream endsof slats 66 rest in corresponding grooves 69 provided in a cross member70 mounted between side frames 38L, 38K.

The lowermost blank of stack 11 is fed onwardly toward the secondstacker 13 by reciprocating feed mechanism 34 and feed rolls 33.Mechanism 34 is conventional. As illustrated herein, a feed mechanismsuch as described in Greenwood Patent No. 2,705,143 issued Mar. 29,1955, is used except that the skip-feed feature described in theGreenwood patent is not required in the present machine. Briefly, thefeed mechanism 34 comprises a Whitworth crank mechanism 72 which impartsreciprocating motion through suitable gearing and levers to a pair ofkicker bars 74L, 74R which are slidably situated in a pair ofcorresponding spaced apart slots 76L, 76K provided in cross member 70. Afeeder bar 78 spans the kicker bars and is secured to the bars at eachend. Feeder tongues 80 are secured to the feeder bar 78 so that thetongues extend forwardly towards the bottommost blank of the stackresting on feed bed 30. The feeder tongues 80 are spaced intermediatethe grooves 69 carrying slats 66 and thus rest on the cross member 70.The forward or leading edge of tongues 80 .are inclined upwardly towardthe rear to a point short of intersection with the top plane of thetongue at which point the incline becomes vertical thus forming a ledge82 which engages the trailing edge of the bottommost blank to urge itforward upon each forward stroke of the feeder bar 78. In this manner,each succeeding bottomrnost blank is fed into the downstreambundle-ejector section until the feeding action is stopped by a feedinterruptor 36.

Feed interruptor 36 comprises a cross shaft 84 rotatably mounted in sideframes 38L, 38R in a position beneath the trailing edge of the stack ofblanks 11 resting on feed bed 30. A number of fingers 86 are spacedalong the shaft and secured to the shaft so as to fit alternatelybetween the slats 66 and feeder tongues 80. Upon the pivoting of crossshaft 84, fingers 86 engage the bottom of the stack 11 and lifts itupward. Now, the ledge 82 of feeding tongues 80 cannot engage thetrailing edge of the bottommost blank.

Shaft 84 is pivoted about 30-60 (the amount is not critical) by aconventional rotary air cylinder 85 attached to one end of the shaft andanchored to one of the side frames 38L or 38R. Air cylinder 85 rotatesshaft 84 in response to a signal from one of four conventional rotarylimit switches N-15, N-Ztl, N-25, N-30, FIG. 5, geared to drive shaft60. An air cylinder such as a ROTA-CYL Model 2.5 made by GrahamEngineering Company, Palo Alto, California, can be used for thispurpose. Shaft 60 completes one revolution for each blank leaving thefolder-gluer. One rotary limit switch N-15 is geared to transmit asignal to the air cylinder 85, for example, after fteen blanks haveentered the hopper, and the remaining three switches N-20, N-25 andN-3t) are geared to transmit signals corresponding to 20, 25 and 30blanks entering the hopper. A selector switch 258 connects the aircylinder to the proper rotary switch corresponding to the number ofblanks desired in the nal stack 15.

Also included in the squaring-compression section is an air holddownassembly 86. As a blank exits from between the pull rolls 22, 24,assembly 86 directs a jet of air against the top trailing edge of eachblank. This forces the trailing edge of the blank down against the topof the stack so that the leading edge of the following blank does notjam against the trailing edge of the foremost blank.

Air holddown assembly 86 comprises an air nozzle 88 in communicationwith a suitable air supply (not shown) and supported on a cross bar 90mounted between side frames 38L, 38R. The support may be in the form ofa collar 92 around cross bar 90 which can be secured in a selectedlateral position by a clamp screw 94. Nozzle 88 is secured to support 92by means of a U-shaped clamp or the like.

Also included in the squaring-compression section is a jam switch 96which, when triggered, will signal the main drive for the folder-gluerto stop its operation. "lfhus, if a jam-up occurs, the machine will stopuntil the obstruction is removed.

J am switch 96 as illustrated in FIG. 2 comprises a flat plate 98 thatis placed between pull rolls 22, 24. The upturned end 100 of plate 98 isspaced in front of the pull rolls to aid in guiding the blanks betweenthe rolls. Plate 98 extends in the space between the collars 23 of upperpull roll 22 so as not to interfere with the pulling action of the rolls22 and 24 against the blanks. Secured to the top of plate 98 is a rod102 which extends through a collar 104 resembling collar 92 and securedin similar fashion to cross lbar 90. A spring 105 between a shoulder 106on rod 102 and the collar 104 maintains the plate 98 in operatingposition. A stop mounted on the opposite end of rod 102 (not shown)prevents the spring 104 from overextending the plate 98 into the path ofthe blanks. If for some reason the stack of blanks 11 builds up to thepoint of interference with blanks leaving the folder-gluer, the plate 98will be elevated and, through rod 102, trigger a conventional limitswitch 103 located adjacent the upper end of rod 102. When triggered bythe rod, switch 103 transmits a signal to stop the main drive motor ofthe folder-gluer. The main drive motor will remain stopped until theplate -98 is returned to its operating position. If preferred, the airholddown assembly can be combined with the jam switch to form anintegral assembly.

The lowermost blank that is fed through the gap 32 between gate 26 andsupport 30 is fed into the second stacker 13 as the lowermost blank ofstack 1-5 by Way of feed rolls 33 which are comprised of a pair ofdriven pull rolls 108, 110. These rolls pull the blanks into thebundleejector 13 as they are fed through the gap 32 formed by thefeedgate 26 and the feed bed 30. The movement of the blank is also aidedby a driven conveyor assembly 112 that has an upper run 114 slightlyhigher than the top of feed bed 30. The upper run is supported on thelower pull roll 110 so that the upper run has an upstream inclinedportion 116 for guiding each blank under the stack being formed.

Stacker 13 also includes a pair of back-stop assemblies 118, 120 againstwhich the blanks are urged by the upper run 114 of conveyor 112 and afront guide 122 to prevent the stack of blanks from tipping over. Anactuator 205, FIGURE 3, pivots the back-stop assemblies 118, 120 about186 out of the path of travel of the blank, following actuation of thefeed interruptor 36. Conveyor assembly 112 now ejects the accumulatedstack 15 of blanks onto an idling roller conveyor 124. At this time, noblanks are being fed from stack 11 into the bundle-ejector sectionbecause fingers 86 have lifted the trailing edge of stack 11 out ofengagement with the feed tongues 80. A manual adjustment 164 adjusts thelineal position of the back-stop assemblies 118, 120 for accommodatingpreselected lengths of blanks. A motor opening assembly (motor M-4, rack213) adjusts the lineal position of the bundle-ejector section 13 inrelation to the squaring-compression section 7 to adjust the lattersection to accommodate the same preselected length of blanks.

Pull rods 108, 110 of feed roll unit 33 are journaled for drivenrotation between spaced apart side frames 44L, 44K at a level to receivein the nip between them the blank that is being fed through the gap 32between feed gate 26 and bed 30 by the reciprocating feed mechanism 34.Advantageously, upper roll 108 is journaled in conventional eccentrics(not shown) which can be rotated in the known manner to move roll 108closer to roll 110 and change the nip openings to suit the caliper ofthe blanks. Lower roll 110 is made by securing several laterally spacedcollars 126 for rotation with a shaft 128 defining spaces 130therebetween. Upper roll 108 is made by securing a correspon-ding numberof laterally spaced collars 132 for rotation with a shaft 134 in radialalignment with lower collars 126. Upper collars 132 are preferably steeland lower collars 126 are preferably covered with synthetic rubberaround their outer periphery. Thus, the

blanks 10 are gripped between the opposing collars 136 and 126 andforced under stack 15 as the lowermost blank.

Conveyor assembly 112 for cooperating with feed roll unit 33 comprises aplurality of conveyor belts 136 eucircling aligned pairs of pulleys 138,140. Pulleys 138 are secured for rotation with a driven pulley shaft 142spaced downstream from lower pull roll 110. Pulleys are mounted aroundbushings (not shown) situated on lower pull roll shaft 128 in the spaces130 between the lower pull roll collars 126. This arrangement permitspulleys 140 to free-wheel around shaft 128. Pulleys 140 have an outerdiameter smaller than the outer diameter of pull roll collars 126 sothat the conveyor belts 136 encircling the pulley do not protrudevertically above the periphery of the lower pull roll collars into thenip between them and the upper pull roll. As best illustrated in FIG. 2,a pair of idler rolls 144, 146 are provided to support the upper run 114of belts 136 at a level slightly higher than the top surface of feed bed30. Preferably, idler rolls 144, 146 are journaled for rotation in slideblocks 148, 150 placed in a slot 152 in side frames 44L, 44R.

The upstream and downstream pairs of slide blocks 148, 150 areadjustable towards and away from each other and can be clamped inposition by any convenient clamping means. Thus, it can be seen thatthis adjustment prolvides means for adjusting the inclined portion 116of belts 135 between lower pull roll 128 and idler roll 144 and aninclined portion 154 between idler roll 146 and pulley shaft 142. It maybe ldesirable to adjust the amount of incline depending on the length ofblank being handled to prevent tipping of the stack. Pulley shaft 142 isdriven at about one-eighth pull roll speed for minimum length blanks andup to one-half pull roll speed for maximum length blanks. This providesan additional measure of control over the blanks to prevent tipping ofthe stack being Iformed.

A conventional belt tightener 156 is provided for maintaining thedesired tension on conveyor belts 136.

Since the dimensions of the blanks being stacked may vary, stacker 13 ismade adjustable. Accordingly, backstop assemblies 118, 120` for thestack 15 of blanks are mount-ed for lateral adjustment on a pair ofcross-rods 158. Cross-rods 158 are supported in slide carriages 160L,160R through which racks 162 pass in meshing engagement with toothedpinions 164 secured to the ends of one of the cross-rods 158 which isrotatable. Racks 162 are supported between upstanding portions 159 ofthe side frames 44L, 44K. An end 164 on the rotatable cross-rod extendsthrough carriage 160L and is adapted to receive a ratchet wrench (notshown) for rotating the cross-rod for moving the carriages 160L, 160Rupstream or downstream. A conventional pinch type clamp 165 is providedon cross-rod end 164 to lock the cross-rod against rotation once it hasbeen rotated to the desired position. In this manner, back-stopassemblies 118, 120 are move-d toward or away from front guide 122 tocorrespond to the length of blanks being handled. It should beunderstood that a suitable gear motor can be provided for rotatableconnection Iwith cross-rod end 164 to replace the manual adjustment justdescribed.

Front guide 122 for the stack 15 comprises an upstanding plate suitablysecured between side frames 44L, 44R immediately behind upper pull rolli108. The top of front guide 122 extends 'a little beyond the maximumheight of the stack to be formed. The bottom of the guide terminatesabove the lower` surface of the upper pull roll 108 so as not tointerfere with the blanks being fed onto the bottom of the stack.

To provide for lateral adjustment of back-stop assemblies 118, 120 toaccommodate the width of the blanks being handled, the back-stopassemblies have corresponding side plates 166, 168. A pair of threadedscrews 170, 172 are provided adjacent to and parallel with cross-rods158. Each threaded screw has threads formed thereon beginning near thelateral center of the machine with the threads on one screw extending tothe left iand on the other to the right-hand side of the machine. A pairof holes 174, 176 are provided in side plates 166, 168 of whichalternate ones are threaded for engagement with one of the pair ofscrews 170, 172 passing through the holes. The unthreaded hole slidesalong the unthreaded portion of the adjacent screw. The ends of screws170, 172 are supported for rotation in slide carriages 1601., 160R.Thus, it can be seen that simultaneous rotation of both screws causesthe back-stop assemblies to eithermove toward or away from the center ofthe machine depending upon the direction of rotation of the screws. Oneend of each threaded screw 170, 172 is secured for driven rotation withone of two gearmotors 174 mounted to slide carriage 168K. Suitablepushbutton controls are provided to run the gearmotors in theappropriate direction to position the backstop assemblies relative tothe center of the machine.

Besides being adjustable to `accommodate various size blanks, back-stopassemblies 118, 120 are designed to arrest for-ward travel of the blanksas a stack is being formed and then to be disengaged from the stack atthe proper interval to permit the stack to be ejected from thebundle-ejector section and onto, for example, a roller table 124 wherethe stack may be tied with string for handling and shipping. This isaccomplished by providing gatestops 180L, 180k, against the leadingedges of the blanks and pivotable about a vertical axis to a positionout of engagement with the stack immediately following engagement offeed interruptor 36. With the gate-stops 180L, 180R out of engagement,conveyor assembly 112, which runs continuously, moves the stack ofblanks downstream for further handling.

Preferably an upstanding side roller 182 is provided to engage each sideof the stack when the gate-stops are re.- tracted to provide a reducedfriction side guiding surface for the stack as it is ejected. Thisroller engages the side of the stack so that all the blanks move forwardsimultaneously.

The construction of the right-hand back-stop assembly 118 may be morereadily understood by reference to FIG. 3 wherein there is illustratedsideplate 168 for loosely engaging the side of the stack. The lowerportion of sideplate 168 terminates just short of touching the tops ofconveyor belts 136 and the upper portion extends above the top of thestack wherein the aforementioned holes for cross-rods 158 and threadedscrews 170, 172 are provided.

A pair of spaced apart upper and lower lugs 184 are formed on theoutside of sideplate 168 between which a pivot rod 186 is supported.Gate-stop 180K includes a pair of arms 188 through which pivot rod 186passes for pivotal support. Another pair of arms 190 are formedsubstantially diametrically opposite arms 188 for mounting side roller182.

Arms 190 include an enlarged portion 192 with a hole 194 through which apin 195 is kept in an extended position by means of a coil spring 196between a shoulder portion 198 Iand enlarged portion 192. Pins 194 havevertically aligned holes 202 for receiving reduced diameter end portions204 of rotatable rubber covered side roller 182.

The geometry of arms 188 and 190 is such that when gate-stop 180R isengaging the leading edges of the blanks, side roller 182 is out ofengagement with the sides of the blanks. When gate-stop 180R is pivotedout of engagement about pivot rod 186, side roller 182 moves intoengagement with the sides of the blanks. The proportions are such thatspring 196 is compressed by engagement of side roller 182 with theblanks so that the roller compensates for any unevenness of the blanks.

The alternate position of the gate-stop and side roller is indicated byphantom lines in FIG. 3. To pivot the gateslop 180R from the engaged tothe disengaged position there is provided a conventional rotary aircylinder 205 (such as described for use with the feed interruptor) whoseoutput shaft 206 is connected to pivot rod 186 by means of meshing spurgears 208 and 210 of which gear 288 is secured for rotation to outputshaft 206 and gear 210 is secured for rotation with pivot rod 186. Sincegatestop 180k preferably rotates about 45 from one position to the otherand output shaft 206 rotates about the ratio of gear 210 is about 2:1With gear 208. This ratio is not critical and other arrangements can beused if desired.

Rotary air cylinder 205 can be mounted by means of suitable brackets(not shown) to side plate 168. A conventional double acting solenoid airvalue is provided in the air supply to cylinder 205 to rotate outputshaft 206 in one desired direction. The valve is triggered by a signalfrom one of the rotary limit switches N-15, N-20, N-25 or N-30 beingused to signal the feed interruptor 36. Thus, when the feed interruptor36 stops the feeding of blanks into the bundle-ejector section 13, thegate-stops L, 188K swing out of contact with the blanks, the siderollers 182 engage the side of the stack, and conveyor 112 moves thestack out of the machine onto idling conveyor 124 for subsequenthandling.

To adjust the lineal position of the bundle-ejector sectiJn in relationto the squaring-compression section to accommodate the selected blanklength, there is provided a pair of rails 212 anchored to the floor.These rails are adapted to guide a number of roller cages 214 secured tothe bottom of side frames 44L, 44R. A toothed rack 213 is secured to theinside wall of each rail 212. Meshing with each rack is a pinion gear onthe output shaft of a pair of miter gear boxes (not shown) each of whichis respectively secured adjacent the rack on the inside of side frames44L, 44K. The gear boxes are linked for simultaneous rotation by a shaftwhich is connected to a gearmotor M-4 mounted to side frame 44L. Thus,upon rotation of gearmotor M-4, the pinion gears meshing with the racks213 pull the bundle-ejector section towards or away from thesquaring-compression section. This, of course, moves feed gate 40 inrelation to the oscillating squaring plate 54 for setting the properdistance between them for the blank selected. The mechanism justdescribed for moving one section relative to another is conventionallyused on box machines such as printer-slotters.

The power train, FIGURE 4, for running the machine is comprised ofconventional elements Stich as chains and sprockets, spur gears, andclutches. The manner in which `thcy are mounted and connected is wellknown in the art so that only a brief description is deemed necessary.Referring now to FIG. 4, the machine is powered by a chain drive 350from a take-off sprocket 352 on the folder-gluer to a sprocket 354 onthe end lof drive shaft 60. Sprocket 354 rotates drive shaft 60 througha conventional manual clutch 356 having an engaging/disengaging handle358. A friction clutch such as bronze bushing type 8B made by Link-BeltCompany, 301 W. Pershing Road, Chicago, Ill., is satisfactory for thispurpose. Its operating handle may be used to disengage the clutch fromthe chain drive. In this manner, the squaring-compression section or thebundle-ejector section can be easily maneuvered. For example, theoscillating squaring plate 54 can be manually pivoted to its extremeupright position for gauging the hopper opening when setting up for adifferent size blank. The chain drive 350 and clutch 356 are enclosed ina suitable guard 360 as shown in FIG. 1.

On the opposite end of drive shaft 60, a spur gear 362 is mounted formeshing engagement with spur gears 364, 366 on the ends of pull rolls 24and 22 through an idler gear 368 mounted to the side frame to providethe correct direction of rotation. Gear 364 rotates lower pull roll 24through an overrunning clutch 221 as previously mentioned, so that whenthe lower roll is rotated by the auxiliary motor M-l, gear 368 does nottry to back-drive the remainder of the machine. A satisfactory clutch toper- 9 form this function is a Formsprag FSO-500 type made by Formsprag,23601 Hoover Road, Warren, Mich.

A crank gear 370 mounted to the side frame is driven by gear 362 througha pair of idler gears 372, 374 which are also mounted to the side frame.The idlers provide the proper `direction of lrotation for crank gear370. As previously mentioned, crank gear 370 is used to providereciprocation of the feed mechanism 34. It has also been pointed outthat a connecting rod 58 between the drive shaft 60 and the squaringplate 54 operates to oscillate the squaring plate.

A bevel gear box 376 is mounted t-o the side frame and connected tocrank gear 370 by an idler 378 also mounted to the side frame. Gear box376 contains conventional bevel gears for changing the output directionof the power train at right angles to the input. This arrangementpermits connection of a line shaft 380 between gear box 3 76 and acorresponding bevel gear box 382 mounted to the side frame of thebundle-ejector section. Power is transmitted to the latter sectionthrough the line shaft 380 where it again changes direction to rotategear 381 on the end of lower pull roll 110 through an idler gear 384mounted to the side frame. The line shaft 380 has a sliding, splinedconnection with bevel gear 386- in gear box 382 so that thebundle-ejector section can be moved toward and away from thesquaring-compression section without affecting the power transmitted byline shaft 380.

A pair of gears 388, 390 on the ends of pull rolls 110 and 108 mesh toprovide driven rotation for upper roll 108.

A variable ratio pulley unit 392 has its input driven from the oppositeend of lower pull roll 110. Input pulley 394 is connected to outputpulley 396 by a belt 398. A hand-rotated control (not shown) is providedfor changing the relative diameters of pulleys 394, 396 to provide avariable output speed on a shaft to which a spocket 400 is mounted. Anexample of a pulley unit satisfactory for this purpose is a variablepulley No. 412 made by Leuellen Manufacturing Company, Columbus, Ind.Conveyor shaft 142 is driven by a sprocket 402 mounted on its endconnected with sprocket 400 by a chain 404. In this manner, the speed ofconveyor 112 can be varied between one-eighth and one-half blank speedas previously pointed out.

The gear and sprocket diameters are chosen to give the ratios requiredt-o operate the various parts of the machine at different speeds, asdesired. Since the selection of such ratios is commonplace, no furtherdescription is considered necessary in this regard.

FIG. 5 is a wiring diagram illustrating the various electrical controlsfor the machine. The portion of the circuit for each control function islabeled to correspond to that portion of the machine being controlled.The motors M1, M2, M3 and M2 are conventional and may, for example, asillustrated be energized by 220/ 440 volt three phase- 60 cycle currentsupplied through leads L1, L2, and L3. The various relays, limitswitches, etc. are energized by 110 v. single -phase 60 cycle currentsupplied through leads X1 and X2 from a contr-ol tranformer 218. A fuse220 is provided in X1 to prevent damage to transformer 218 in the eventof a malfunction.

The first control function is for the pull rolls 22 and 24 for whichprovision is made to keep the rolls rotating for a predetermined lengthof time after the main drive is stopped so that the last blank leavingthe folder-gluer will be fed into the squaring-compression section, andto permit manual control of the rolls during set-up of the machine or toclear a jam-up.

Unidirectional motor M1is provided to rotate pull rolls 22 and 24through a conventional overrunnig clutch 221 mounted to one end of thelower roll 24. The upper roll 22 is driven by a gear 366 mounted on oneend in mesh with a gear 364 mounted on the corresponding end of thelower roll 24.

To control motor M1 the control circuit is divided into a manual andautomatic portion. The automatic portion comprises an auto-manual switch224 (common to -both portions of the circuit) in series with CR contacts(control relay) located inthe main drive cabinet for the foldergluer. CRcontacts automatically close when the main drive is energized and withthe auto-manual switch on automatic, the circuit is completed toenergize motor M1. When this portion of the circuit is completed, a coilTD1 is energized to close relay contacts N1 (230) in the supply line tomotor M1. Coil TD1 also closes time delay relay contacts TD1 (231) whichremain closed X seconds after coil TD1 is deenergized (X can beadjusted). Thus, when the main drive is stopped, CR contacts open,breaking the circuit. But, time delay relay contacts TD1 cornplete thecircuit through push-pull switch 226 (in the start position), thus, coilN1 is energized to keep contacts N1 closed to energize -motor M1. AfterX seconds have elapsed, time delay contacts TD1 open, breaking thecircuit to the motor. In this manner, the pull rolls are rotated bymotor M1 for X seconds after the main drive is stopped.

To operate motor M1 manually, switch 224 is pushed to the manualposition. Push-pull switch 226 is pulled to the start position. Startbutton 228 is pushed which completes the circuit through coil N1 whichcloses relay contacts N1 (231)) after which start button 228 may bereleased. Contacts 230 complete the circuit to motor M1.

It will be observed that there are thermal overload switches NlOL in theline between relay contacts N1 and motor M1. These contacts open in theevent of overload and automatically open the normally closed reset relaycontacts N1 in the manual circuit. When the overload ceases, resetcontacts N1 are used to reset overload switches N1OL. In the event of anoverload occurrence when operating in the automatic mode, similar resetcontacts are opened in the main drive (not shown).

Each of the other circuits shown contain similar overload and resetrelay switches and no further description of these is necessary.

Each of the backstop assemblies 118 and 120 are laterally positioned bymotors M2 and M3 as previously described. Since the control circuits areidentical for each motor, only the circuit for motor M2 will bedescribed. The circuit is divided into two portions, one of which closesrelay contacts N2 (232) to run motor M2 in one direction and the otherwhich closes contacts N2 (234) to run motor M2 in the oppositedirection. A three-position selector switch 235 is common to bothportions and when in the in position completes the circuit through anormally closed limit switch LS1, a normally closed relay N2 (238), acoil N2 and a normally closed reset relay N2. With the circuitcompleted, coil N2 closes contacts N2 (232) to motor M2. Coil N2 alsoopens normally closed relay N2 (242), as a safety precaution, to preventaccidental closing of both contacts N2 (232 and 234) simultaneously. Theother portion of the circuit operates in similar fashion when theselector switch 235 is in the out position. In this position, coil N2(246) opens normally closed relay N2 (238).

The limit switches LS1 and L82 are mounted on sorne stationary portionof the machine with LS1 being near the center of the machine and LS2being near the side frame in alignment with the backstop assembly 118.They are positioned to limit the amount of lateral travel of thebackstop assembly so that it does not move too far in either direction.When the backstop assembly hits either of the switches, the circuit isbroken and the selector switch 235 must be turned to the oppositeposition to operate the motor M2 in the opposite direction. This willrestore the activated limit switch to its normal position.

The motor opening circuit is used to control motor M4 to adjust thebundle-ejector section 13 in relation to the squaring-compressionsection 7. Motor M4 is reversible and controlled by a divided circuitsimilar to the circuit used for the backstop assemblies. There are twodifferences, of which the first is the limit switches LSS and LS6'.These switches are mounted to the side rail 212 in a position to beactuated respectively by a cam 237 secured to the frame 44L. The purposeof the switches is to prevent the bundle-ejector section from beingpositioned beyond designed for maximum and minimum distances from thesquaring-compression section.

Also shown in the motor opening circuit are opening circuit jacks 248which are provided as a matter of convenience to permit the selectorswitch 250 to be plugged into the circuit.

The remainder of the control circuit is for controlling the feedinterruptor 36 and the pivoting backstop assemblies 118 and 120. Therotary air cylinder 85 previously mentioned rotates clockwise orcounterclockwise in response to pressurized air directed in theappropriate directions by a solenoid operated air valve. Rotation of theair cylinder raises or lowers the stack of blanks by the rotation offingers 86.

The rotary air cylinder 205 previously mentioned pivot-s the stop-gatesIStlL, 180R in the appropriate direction in the same manner.

The air solenoid for operating the feed interruptor 36 is illustrated at254 and the air solenoid for operating the stop-gates 1801., 180R isillustrated at 256. These solenoids are energized by one of fourseparate circuits designated as N-15, N-20, N-25 and N-30. Each of thesecircuits are energized by a selector switch 258 which is manually turnedto place the desired pair of contacts in series with one of circuitsN-IS, N-20, N-25 or N-30. Each of the latter circuits compriseconventional rotary limit switches geared to drive shaft 60 so that N-15will operate after the drive shaft has rotated l revolutions; N-20 willoperate after the drive shaft has rotated revolutions and so on. Sinceone blank enters the squaring-compression section hopper for eachrevolution of the drive shaft and the remainder of the machine is intimed sequence, it is obvious that a stack in the bundle-ejector sectionwill be dicharged with the desired number of blanks as selected byselector switch 258.

Each rotary limit switch has cooperating pairs of contacts S1, S2, S3,and S4. The switch is arranged so that upon operation after the correctnumber of revolutions of the drive shaft 60 occurs, S1 contacts close toenergize solenoid 254 to actuate the feed interruptor. Thereafter, S3contacts close to energize solenoid 256 to pivot gatestops 180L, 180Rout of engagement with the stack in the bundle-ejector section. Theswitch is adjustable to vary the time interval between closing ofcontacts S1 and S3. The adjustment is made to allow sufiicient time forthe last blank being fed, after actuation of the feed interruptor, tocontact the gate-stops before they are opened to discharge the finalstack. Thereafter, contacts S2 and S4 close simultaneously to energizeboth solenoids 254 and 256 to return the feed interruptor 36 and thegate-stops 180L, 180R to their original positions for the next cycle. Anexample of a rotary limit switch suitable for this purpose is a standard4 cam type 200G-92 made by Gemco Electric Company, Clawson, Mich.

It should be understood that other type switches can be used to countthe blanks and at other locations on the machine. For example,ratchet-type limit switches could be provided for triggering by theleading edge of the blanks as they enter gap 32 between feed bed 30 andfeed gate 40. Four switches could be used of which one would furnish asignal after being triggered l5 times, another would furnish a signalafter 2O times and so on. A selector switch as described above would beused to determine which limit switch was to be activated.

Operation To operate the machine, one of the blanks to be handled isplaced on the feed bed 30 with its trailing edge resting against theoscillating squaring plate 54 which is in the upright position. (Thisposition can be obtained by jogging the machine by actuating the maindrive control until the plate is vertical.) The selector switch 250 isused to move the bundle-ejector section towards (or away from) thesquaring-compression section until the feed gate 40 rests looselyagainst the leading edge of the blank.

The same blank may then be used to set up the bundleejector section byplacing the blank on the conveyor 112 with its trailing edge restingagainst front guide 122. Shaft end 164 is rotated manually to move thegate stop assemblies 118, loosely against the leading edge of the blank.Shaft 158 may be locked in position by clamp 165. Switches 235 may thenbe used to operate motors M2 and M3 to move the backstop assemblies 118and 120 into edgewise contact with the blank. If desired, the inclinedportion 116 of conveyor 112 may be adjusted to suit the length of blankbeing handled.

If the thickness of the blanks is different from the preceding order,both upper pull rolls 22 and 108 may be adjusted to give the proper gapbetween them and the lower pull rolls 24 and 110.

A stack of blanks is then placed in the squaring-compression sectionhopper to the height of the oscillating plate 54. The pull roll driveselector switch 224 is placed on automatic. The bundle selector switch258 is positioned to the selected number of blanks desired in the finalstack. The machine is now ready to run.

The ratios of the gears in the power train is such that the pull rolls22 and 24 in the squaring-compression section rotate at blank speed. Thedrive shaft 60 also rotates at blank speed, that is, it makes onerevolution for each blank entering the hopper. Thus, the rotary limitswitches N-15, N-20, N-25 and N-30 geared to the drive shaft determinethe desired number of blanks in the final stack by counting theappropriate number of revolutions of the drive shaft.

A factor in the successful operation of the machine lies in running thefeed mechanism 34 to remove blanks from the first stack 11, during thefeed cycle, at a faster rate than they are deposited on top of thisstack. Otherwise, during a dwell period of the cycle, i.e., the timethat feed interruptor 36 is operative to permit discharging the finalstack 15 from the bundle-ejector section 13, the blanks from thefolder-gluer would pile up on top of the stack and jam the machine.Thus, by removing more blanks than are added in an interval of time, areservoir on top of the stack is created to store the blanks addedduring the discharge cycle. As an example of the operation, thefolder-gluer supplies blanks to rolls 22, 24 at the rate of 5 persecond, feeder 34 operates for 2 seconds and the interruptor 36maintains the feeder in a dwell period for 1 second. Then l0 blanks areadded to the stack 11 in 2 seconds. The discharge cycle for stack 15which is to contain 15 blanks requires one second, i.e., it is operativeto discharge during the dwell period. The l5 blanks are removed from thestack 11 in two seconds. This depletes the reservoir of stack 11 by 5additional blanks during the two second interval in which blanks arebeing fed from stack 11 but this number is replenished during the onesecond discharge interval during which a dwell period exists in the feedto stack 15.

Suitable ratios for the gears in the power train to establish this rateare provided in accordance with wellknown formulae for such gears.

The pull rolls 108 and 110 in the bundle-ejector section run faster thanthe blanks are fed by the feed mechanism 34. This will result in a spacebetween succeeding blanks passing between the pull rolls to insure thatthe trailing edge of the preceding blank has cleared the pull rollsbefore the next blank is fed. Otherwise, the blanks would not be fed oneunder the other.

Having thus described my invention in its best embodiment and mode ofoperation, what I desire to claim by Letters Patent is:

1. Apparatus for forming a final stack of blanks of predetermined numberfrom a sequential supply of said blanks, comprising:

first stacking means receiving blanks from said sequential supply forforming a first stack of blanks; final stacking means for forming saidfinal stack of blanks; feeding means forming a part of said firststacking means and engaging said first stack for feeding blanksconsecutively from said first stack to the underside of said final stackat a rate faster than the rate at which blanks are received by saidfirst stack; said final stacking means including a continuously drivenconveyor having an upper run forming the bottom of said final stackingmeans and supporting said final stack and having an inclined portion forreceiving blanks from said first stack; interrupting means fordisengaging said first stack from said feeding means to yinterrupt theow of blanks to said final stack when the final stack contains saidpredetermined number of blanks; discharging means for discharging saidfinal stack of blanks from said final stacking means during saidinterruption of flow of blanks from said first stacking means, saiddischarging means including a pair of back-stops each having a firstportion for engaging the leading edge of said blank to arrest theforward travel and a second portion for engaging the lateral edges ofsaid blanks; and actuator means operative during the interruption of theow of yblanks for moving said first portion of said back-stops out ofengagement with said leading edges and said second portion intoengagement with the lateral edges of said blanks so that said conveyorunoves the stack forward to discharge it from said final stacking means.2. The apparatus of claim 1, and in addition: adjusting means forvarying the size of said first and final stacking means to correspond tothe blank size being handled, comprising:

mounting means for fixing said feed gate to said final stacking means;first adjusting means for moving said final stacking means lineallyrelative to said first stacking means whereby the space between saidfeed gate and said squaring means is varied to correspond to the lengthof the blanks; second adjusting means connecting said back-stops forlineal adjustment relative to the inclined portion of said conveyorwhereby the space dened -by said back-stops and said inclined portion isvaried to correspond to the length of blanks; and

third adjusting means connecting said back-stops for lateral adjustmentrelative to one another whereby the space between the back-stops lisvaried to correspond to the width of the blanks.

3. The apparatus of claim 2, and in addition:

pneumatic pressure means comprising a nozzle secured to said firststacking means adjacent said trailing edge of the blanks lin said firststack and in communication with a supply of air under pressure fordirecting a jet of air against the trailing edge of the blank enteringsaid first stacking means to prevent the leading edge of the successiveblank from jamming against the trailing edge of the preceding blank.

y4. The apparatus of claim 2, and in addition:

a jam switch for shutting down a main drive motor in response to jammedconditions within said first stacking means comprising a plate and asignal means, said plate being located in a normal position immediatelyabove the level of travel of blanks entering said first stacking meansand in resilient engagement with said signal means for actuating thelatter to signal said drive motor in response to a displacement of Saidplate from said normal position.

References Cited UNITED STATES PATENTS 1,865,308 6/1932 Evans et al.214-6 X 2,133,260 10/1938 Wolff 271-86 X 2,466,544 4/ 1949 Harred 214-6X 2,697,388 12/1954 Hansen et al 214-6 X 2,779,592 1/ 1957 Hartman.2,963,177 12/ 1960 Shields 214-6 3,122,242 2/1964 Lopez et al 214-63,194,127 7/1965 Larsson 214-6 X 3,334,784 8/1967 Morrison 221-13 X3,345,063 10/ 1967 Swanson.

FOREIGN PATENTS 791,600 3/ 1958 Great Britain.

GERALD M. FORLENZA, Primary Examiner.

R. .T SPAR, Assistant Examiner.

U.S. Cl. X.R.

